Solenoid; Fuse - Pioneer 1200 Maintenance Service Manual

ELECTRICAL COMPONENTS: FE400 ENGINE

SOLENOID

See General Warning, Section 1, Page 1-1.
Testing the Solenoid
See Test Procedure 6, Section 11, Page 11-26.
Solenoid Removal
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Disconnect the battery cables as instructed (Figure 12-1, Page 12-1). See WARNING "To avoid unin-
tentionally starting..." in General Warning, Section 1, Page 1-1.
3. Remove electrical component box cover.
4. Disconnect all the wires from the solenoid.
5. Remove the two screws securing the solenoid in place.
Solenoid Installation
1. Install the solenoid in the electrical component box using two screws to secure the solenoid to the box
and tighten to 14 in-lb (1.6 N·m). See following WARNING.
∆
WARNING
• Incorrect wiring could result in severe injury or death.
• Diode and solenoid connections must have correct polarity.
• Keep all persons clear of engine belts when making final connections.
2. Connect all wires as indicated.
2.1. Connect the 6-gauge white wire from the starter/generator, 18-gauge red wire from the voltage reg-
ulator, and the 12-gauge white wire from the diode to the large post on the solenoid. See Wiring
Diagram, Section 11, Page 11-6.
2.2. Connect the 6-gauge red wire from the battery, the 10-gauge red wire from the fuse block, and the
12-gauge red wire from the diode to the other large post on the solenoid.
2.3. Connect the 18-gauge blue wire from the key switch to the small post on the solenoid.
2.4. Connect the 18-gauge green wire from the Forward/Reverse limit switch to the other small post on
the solenoid.
3. Tighten the hex nuts on the large solenoid posts to 60 in-lb (6.8 N·m). Tighten the nuts on the small sole-
noid posts to 22 in-lb (2.5 N·m).
4. Install the snap-on electrical box cover by firmly pressing down on all corners and install the screw and
tighten to 18 in-lb (2 N·m).
5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat
terminals with Battery Terminal Protector Spray (CCI P/N 1014305).

FUSE

See General Warning, Section 1, Page 1-1.
Testing the Fuse
See Test Procedure 2, Section 11, Page 11-23.
Fuse Removal
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
12
Solenoid
Page 12-15